Saturday, July 6, 2019

Harnessing the Power

Recently when examining one of the spark plugs on the Pulsar NX, I found that the ignition wiring harness was in poor shape with every coil connector broken and held in place by friction only.  I found replacement connectors on eBay for $2 each.  


To get the harness out of the car, the intake must be removed as well as the cover over the ignition coils.


The harness can then be removed by removing the coil connectors as well as two connectors near the airbox and a ground wire.  You can see in this pic how degraded the coil connectors had become.  Once removed I stripped the sheathing from the harness so that I could access each wire.


Working one connector at a time and one wire at a time, I cut the old connector off and soldered in the replacement.  Heat-shrink tubing was used over each splice and electrical tape was used to wrap the entire harness once complete.


Before replacing the harness I took the time to clean and inspect each coil pack.  I removed dirt and carbon from the bit that contacts the spark plug and applied a light coating of dielectric grease to help prevent arcing.


Once the coil packs were back in place the harness was ready for re-installation.


Once the cover and intake tube were back in place a quick test drive was taken to ensure all was in working order.